Paul & Sabrina's cheap DIY 144v motor controller

[thingstodo]

Originally Posted by chinuhark

Paul, First up you're a god. I've been looking over this thread now and then for maybe an year now and you have finally made me register on the forum and get back into trying to do vector control.

I think maybe this post was supposed to go here? http://ecomodder.com/forum/showthrea...tml#post498094

EDIT - I guess you did! My bad - I didn't look before posting!

[duncan]

Hi Paul

Didn't get a Leaf pack - I've got a Volt pack! - waiting for it to come over on the ship
So 388v ???

Or should I try and turn it into two strings?

My new shed currently consists of 10 poles concreted into the ground but I have finished the kitchen so I'm allowed to work on it

[MPaulHolmes]

In theory 388v should be fine. in theory... haha. They are 600v components, so I doubt 388v is a concern. How much is it fully charged?

[duncan]

Hi Paul

I think 388v is fully charged - I'll have to do some studying before it arrives

Thanks

[MPaulHolmes]

Then if the motor will be OK with it, I'd go ahead and use 388v. 388v at 1200amp is a lot of power. I think you could beat the crap out of those fancy cars in the drag race then. And if that doesn't work, just slash their tires. haha

[Bela]

Finally finished up the Open Revolt controller and it works! At least with 12 volts.

Below is the Open Revolt board along with the Raspberry Pi that reads the RS232 output of the Open Revolt board and allows me to view it in a browser. Used ShellInABox and it works great. The custom board has some extra electronics to monitor the battery and motor voltage as well as some opto-isolators to isolate the Open Revolt from the raspberry pi.


The inside of the box is cramped but everything fits. On the right side are 2 smaller relays. One is for the precharge circuit and the other is to control a pump for cooling the IGBTs.


Decided to have some fun with the box and made the top a flux capacitor. The rasperry pi controls the animation on the flux capacitor. The idea is to setup a web server on the raspberry pi so that the animations can be controlled using a browser.

[MPaulHolmes]

Oh my gosh that turned out awesome!!! How did you do the liquid cooling? Your fabrication skills are amazing. I love the Flux Capacitor. I have several questions but it is too late and my wife wants to go to sleep haha. I'll ask tomorrow.

[thingstodo]

Originally Posted by Bela

The inside of the box is cramped but everything fits. On the right side are 2 smaller relays. One is for the precharge circuit and the other is to control a pump for cooling the IGBTs.

+1 on how did you do your liquid cooling

[Piotrsko]

VOLT packs can be up to 398 v if you dont mind being risky at 4.145 a cell. Gives you 2.5 ish more KWH. On my ranger split pack I'm running 197 volts for 394 total last two years.

Imho even with 600v components thar be huge spikes that might fry capacitors. Sol1 controller are built that way but delimited to 340 as safety measure. Kinda pissy using volt packs......

I have seen the 500 vdc meter peg while the field collapses on abrupt off throttle overspeed. Don't know by how much overpeg, but.........

[Bela]

For the water cooling I milled out grooves in the base plate right under the IGBTs. The plate is 3/4 inch thick so there was enough depth for it. This really isn't my idea, I borrowed it from forum member 64jeep. It was in his electric porsche blog.


In the side of the plate I drilled 2 holes and then tapped them to run the water lines.


Most likely I will be using a motorcycle radiator to cool the fluid and a swifttech pump for circulation.